Building modules and assemblies made from such modules

ABSTRACT

Each module includes a tubular member filled with filling material, such as concrete, and a tube located in the filling material and extending longitudinally of the tubular member. Tubes or holes extend transversely through the tubular member and the filling material. The longitudinal tube facilitates connection of the module in end-to-end relationship with the modules using connecting mechanisms. The transverse tubes or holes facilitate securing the module to one or more like modules in side-by-side relationship using securing mechanisms. The modules may be assembled together so as to form, for example, a pipeline stabilizing and protection mat to ballast and protect underwater pipelines.

This invention relates to building modules and building assembliesconstructed from such modules such as stabilising and protection matsused to ballast and protect underwater installations, particularly, gasor oil pipelines on the sea bed or river bed.

It is known that such mats may comprise a plurality of elongate castconcrete bars disposed in side-by-side spaced relationship with eachother and connected together by flexible connectors so as in use toenable the flexible mat to be draped over or against a pipeline (usuallywith the assistance of divers) with its ends resting on the sea or riverbed at either or both sides of the pipeline. In practice, a number ofthese mats are draped at intervals along a length of the pipelineconsidered in need of ballasting and protection particularly from theundesirable effects of erosion of the sedimentary bed, scouring, anddamage sometimes caused by trawler line tackle and the dragging of shipsanchors or anchor cables which can result in the loss of areas ofconcrete coating usually applied to the exterior surfaces of a pipeline.

Known mats of the kind referred to above have been found to be veryexpensive since they require significant amounts of capital investment,time and labour in providing and setting up moulds or shuttering whichhave to be retained during at least partial curing of the concrete. Alsoadditional time has to be allowed for complete concrete curing after themoulds are removed before the mats can be used. Thus, the cost ofproducing many hundreds of these known kinds of mats required tostabilize and protect e.g., many miles of natural gas offshore pipelinesare thought to be unacceptably high.

Applicants UK patent specification publication No. 2178127 discloses amethod of manufacturing a flexible pipeline stabilizing and protectionmat, in which there is provided a plurality of elongate tubular membersclosed at one end thereof. Each tubular member is formed with pairs ofholes longitudinally spaced apart along its length, the holes of eachpair of holes being substantially co-aligned in diametrically opposedwalls of the tubular member. Lengths of flexible rope are threadedthrough the respective aligned pairs of holes of the tubular memberswhich are arranged in predetermined spaced parallel relationship witheach other along the ropes. The first and last tubular members of saidplurality of tubular members are provided with hook means. The tubularmembers are then filled from their open ends with concrete whichcompletely encapsulate and anchor the portions of rope contained withinthe tubular members which become a permanently retained encasement partof each of the flexibly interconnected bars formed thereby.

One object of the invention is to provide a building module or unitwhich is constructed to facilitate its connection or securement to likemodules in end-to-end relationship and/or in side-by-side relationship.

From one aspect the invention provides a building module comprising atubular member filled with filling material and means located inposition in the tubular member and associated with an end of the tubularmember for facilitating connection of the module in end-to-endrelationship with another like module using a connecting means toconnect the two modules.

Conveniently, the connection-facilitating means may be associated withboth ends of the tubular member so as to facilitate the connection ofother like modules in end-to-end relationship to either or each end ofthe module. In this case the connection-facilitating means may be a tubethat is located in the filling material and extends longitudinally ofthe tubular member. The tube may be a substantially plain bore tubethrough which connecting means such as a prestressed tendon or rod canpass to connect a plurality of like modules together. Alternatively, thetube may be internally screw-threaded so as to receive externallyscrew-threaded connecting means to connect the module to a like adjacentmodule.

The connecting means may be located or fixed in position in the tubularmember by being mounted from the wall of the tubular member, forexample, by means of one or more support members.

Alternatively, when the filling material is one which `sets` or hardens,the connecting means may be located or fixed in position by virtue ofthe connecting means being encapsulated in the set or hardened material.

From another aspect the invention provides a building module comprisinga tubular member filled with filling material and a bore hole, or tubemeans defining a hole, which extends transversely through the tubularmember and which connects two apertures provided in the wall of thetubular member to facilitate securing the module to one or more likemodules in generally side-by-side relationship using securing meanswhich passes through the bore hole or tube means in the modules.

It will be appreciated that a module may comprise both one or more saidholes or tube means extending transversely through the tubular memberand filling material and said connection-facilitating means so that aplurality of the modules can be linked together in generallyside-by-side and/or end-to-end relationship(s) to form assemblies.

From a further aspect the invention provides a method of making abuilding module, wherein there is provided a tubular member, the methodcomprising filling the tubular member with filling material and locatingin a position associated with one end of the tubular member, to form themodule, means for facilitating connection of the module in end-to-endrelationship with another like module. The connection-facilitating meansmay be located in position by being mounted from the wall of the tubularmember, in which case if the filling material is non-setting ornon-hardening then any openings in the tubular member via which suchmaterial could be lost are closed or plugged.

When the filling material sets or hardens, the material itself may beused to locate the connection-facilitating means in position. Moreoverthe transverse bore holes can be drilled or otherwise produced in thetubular member and filling material after the latter has set orhardened.

Alternatively, the tube means defining the transverse hole may beconnected to two apertures provided in the wall of the tubular memberprior to filling the tubular member with filling material.

The tubular members may be formed from plastics material, for example,polythene or polypropylene which has the advantages of being resistantto impact damage, and which can conveniently be cut lengths of readilyavailable piping. When the modules are assembled into pipe stabilisationmats it is convenient if the plastics material of the members are of aneasily recognisable bright colour so that the mats are more easilylocated in a murky environment which may be found on the sea bed. Atleast one of the centrally located tubular members may be of acontrasting bright colour to the remaining members so as to enable thedivers to more easily manoeuvre the mat centrally over the pipeline.

The use of tubular members made of plastics material also facilitatesthe production of cross-sectional shapes for the finished modules moresuitable for encouraging precipitation of water borne sediment tobetween the gaps of the modules so as to build up the sea-bed under themat and prevent seabed scouring. For example, all or selected ones ofthe tubular members in a mat may be formed with one or more vanes, ribs,fins, spikes, or corners projecting outwardly from their outer surfacefor the purpose of generating water current vortices which causessediment to drop between the bars.

It will be appreciated that the modules may be connected together intostructural assemblies other than pipe stabilisation mats, with orwithout spacing between the modules.

For example, it is envisaged that the modules may be used to constructsub-sea dams to contain drill cuttings, pipe tunnels, culverts, pipesupports, large enclosed forms for containing concrete or grout,removable or permanent wall systems, fences, sign supports on roads orelsewhere, traffic control road markers, stacked to form grout bagsupports for large freespan corrections on pipelines, pipe bridges,screens and baffles.

The width and length of the tubular members and their colour, theparticular construction of the modules and the type and properties ofthe filling material would be selected in accordance with the intendedapplication of the assembled modules.

The filling material when a setting or hardening material may, forexample, be a concrete or grout, or a foam material such as foamconcrete or polyurethane foam. When the filling material is anon-setting material, it may, for example, be sand, gravel or highdensity aggregates.

The present invention will now be described by way of example only withreference to the accompanying drawings in which;

FIG. 1 is a schematic plan view of one form of pipeline stabilising andprotection mat constructed from building modules according to theinvention connected together side-by-side,

FIG. 2 is a similar plan view of a larger form of mat which isconstructed of building modules connected together side-by-side andend-to-end,

FIG. 3 is a sectional view of part of one side of the mat in FIG. 2showing in more detail the modules and the connections therebetween, and

FIG. 4 is a sectional view on the line IV--IV of FIG. 3.

Referring to FIG. 1, the mat comprises a row of elongate rigid modules 1which are connected together in side-by-side relationship by two lengthsof securing means 2.

In FIG. 2, the mat comprises two equivalent rows of elongate rigidmodules 1. Each row is similar to the row shown in FIG. 1. Correspondingmodules in the rows are connected together in end-to-end relationship byconnection means 3.

Conveniently, the first and last modules in the rows in both FIGS. 1 and2, are provided with hook means 4 of suitable form for connection tolifting apparatus, for example, on a supply vessel, for lifting and thenlowering the mat towards a pipeline over which the mat is to bepositioned.

Referring also to FIGS. 3 and 4, in the manufacture of a mat tubularmembers 5 formed from cut lengths of polythene piping are closed attheir lower ends by fixed end caps 6 and are provided with pairs ofoff-centre generally opposing apertures 7, 8 formed in the walls of thetubular members. The opposing apertures in each tubular member areconnected by tubes 9 for facilitating side-by-side connection of themodules. The tubes 9 are, for example, welded to the walls of thetubular members in the regions of the apertures. In cases where it isthought desirable to reinforce the modules to be made, a number ofreinforcing metal rods 10 and/or a reinforcing wire cage 10a aresupported by any suitable means (not shown) within each tubular memberleaving a clearance from each end thereof.

Extending longitudinally and centrally through each tubular member 5 isa connection-facilitating means in the form of a straight tube 11 or 12.The ends of the tubes 11 in the tubular members are internally screwthreaded as at 13 to receive externally screw threaded portions 14a ofconnecting means 14. Each connecting means 14 is used to connect twomodules end-to-end.

The ends of the tubes 12 in the tubular members are not screw threaded.Tubes 12 are for receiving therethrough prestressed rods, wires, tendonsor the like 15 which have threaded ends (not shown) and which aretightened by means of nuts 16.

Each securing means 20 consists of a length of polypropylene rope, a rodor tendon which is threaded through the appropriate tubes 9 of thetubular members which are to form each row. The tubular members 5 arepositioned vertically in side-by-side relationship, e.g. in a suitablejig (not shown), so as to be spaced apart from each other. The ropes,rods or tendons 20 are passed through the aligned tubes and are thenpulled and held taut or stressed in a suitable manner at each end of therow as at 21 (shown only at one end of the row).

The spacing apart of the tubular members may be determined by spacerrings 22 through which the ropes, rods or tendons 20 will also bethreaded alternately with an adjacent tubular member.

Each of the hook means 4 comprises an anchoring part 4a to secure it inthe aperture 23 and an eye bolt part 4b. The eye bolt 4b may bereleasably attached to the anchoring part for re-use with anchoringparts of other mats.

The tubular members 5 in each row, arranged as just described and beforeconnection to another row, are then filled from their open ends forexample by pouring and vibrating a concrete mix 24 so as to completelyencapsulate the tubes 9, 11, 12, the reinforcing rods 10 or wire cage10a (where used) and the anchoring parts 4a of the hook means. Thecompleted row or mat made up of the modules can be removed safely fromthe jig immediately the concrete filling has `set` sufficiently.

When it is desired to form a mat comprising one or more further rows ofmodules, opposing ends of corresponding modules may be connected byconnecting means 14 having threaded ends 14a which screw into the endsof the tubes 11. Alternatively, the tubes 12 in the different rows maybe held in alignment, and rods or tendons 15 may then by passed throughthe tubes 12 and stressed and secured in position by turning nuts 16 topositions whereat they abut the remote ends of the modules.

Depending upon the overall weight of mats required for a particularapplication, the quantity and density of the solid aggregate used in theconcrete mix may be varied both in seive sizing and material whichcould, for example, include iron ore fragments.

It will be understood, as mentioned earlier, that the tubular members(and thus the modules) can be assembled and connected together invarious ways to produce different constructions, depending, for example,on the location of and the angles at which the tube or holes extendtransversely through the tubular members and on the kind and design ofthe securing means and connecting means such as rods or tendons used toassemble the modules together.

I claim:
 1. A building module comprising a tubular member filled withfilling material and means fixedly secured in the tubular member andassociated with an end of the tubular member for facilitating connectionof the module in end-to-end relationship with another like module usinga connecting means to connect the two modules.
 2. A module as claimed inclaim 1, in which the connection-facilitating means is associated withboth ends of the tubular member so as to facilitate the connection ofother like modules in end-to-end relationship to each end of the module.3. A module as claimed in claim 2, in which the connection-facilitatingmeans comprises a tube that is located in the filling material andextends longitudinally of the tubular member.
 4. A module as claimed inclaim 3, in which the tube is internally screw-threaded so as to receiveexternally screw-threaded connecting means.
 5. A module as claimed inclaim 1, further comprising one or more holes extending transverselythrough the tubular member and the filling material to facilitatesecuring the module to one or more like modules in side-by-siderelationship using a securing means which passes through the holes inthe modules.
 6. A module as claimed in claim 5, in which the or eachhole is defined by a tube means which connects two apertures provided inthe wall of the tubular member.
 7. An assembly comprising a plurality ofbuilding modules as claimed in claim 1 connected together in end-to-endrelationship by connecting means linking the modules together via theirconnection-facilitating means.
 8. An assembly comprising a plurality ofbuilding modules as claimed in claim 7 connected together in generallyside-by-side relationship by securing means passing transversely throughthe modules.
 9. An assembly according to claim 7 in which saidconnecting means comprise a rigid member rigidly linking the modulestogether.
 10. An assembly according to claim 9 in which said rigidmember rigidly links the modules together via screw threaded engagementwith said connection-facilitating means.
 11. An assembly according toclaim 7 in which said connection-facilitating means comprises a tubethat is located in the filling material and extends longitudinally ofthe tubular member.
 12. A method of making a building module comprisingfilling a tubular member with filling material, and fixedly securing, ina position associated with one end of the tubular member, means forfacilitating connection of the module in end-to-end relationship withanother like module.
 13. A method as claimed in claim 12, in which theconnection-facilitating means is fixedly secured in position by beingmounted from the wall of the tubular member.
 14. A method as claimed inclaim 13, in which the filling material is non-setting or non-hardeningand in which the tubular member has an opening through which the fillingmaterial may pass out of the tubular member, said method furthercomprising closing or plugging said opening to prevent said fillingmaterial from passing out of the tubular member through said opening.15. A method as claimed in claim 12, in which the filling material setsor hardens and thereby fixedly secures the connection-facilitating meansin position.
 16. A method as claimed in claim 15, in which after thefilling material has set or hardened, one or more bore holes areproduced that extend transversely through the tubular member and thefilling material.
 17. A method as claimed in claim 12 in which theconnection-facilitating means comprises a tube that extendslongitudinally in the tubular member to facilitate said connection atboth ends of the tubular member.